INSTALLATION MANUAL MODEL RP-150

INSTALLATION MANUAL FOR 24 VALVE 5.9L CUMMINS POWERED DODGE TRUCKS 2003 THROUGH 2004.5 MODEL RP-150 READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION 5400 BUSINESS 50 WEST SUITE 8 573 635-0555 VOICE JEFFERSON CITY, MO 65109 573 635-0778 FAX www.pureflowtechnologies.com

"Many thanks to Richard and Glacier Diesel Power for the photographs contributed for use in this manual!" 2

OVERVIEW Welcome to the Raptor Fuel Pump The Raptor Fuel Pump RP-150 is a Premium replacement lift pump for the Dodge Cummins 24 Valve 5.9L diesel engine. A complete installation kit is included. The Raptor RP-150 flows 150 GPH and is recommended for highly modified 5.9L Cummins Diesels producing in access of 1,200 HP. The high fuel flow of the Raptor RP-150 requires a ½ suction tube which is included in the installation kit. The Raptor, a gearotor fuel pump, features an adjustable pressure regulator and is also available as the RP-100. The Raptor RP-100, which flows 100GPH, is recommended for stock and slightly modified 5.9L Cummins Diesels up to 550+ HP. PureFlow products are manufactured with a personal touch, unsurpassed attention to detail and the most stringent quality control! The installation of the Raptor RP-150 Fuel Pump can be made relatively easy by following the steps outlined in this manual. 1. Inventory the package components completely. Notify PUREFLOW TECHNOLOGIES, INC. Immediately of any parts missing or damaged. 2. Read the owner s manual and the installation manual completely. Understand how the system operates and installation recommendations before beginning installation. 3. The installation recommendations contained herein are suggested installation guidelines only. Individual installations may vary. 4. Use good judgment and common sense when installing the Raptor 150 Fuel Pump 5. Uncertain about any installation procedures? Contact PUREFLOW TECHNOLOGIES, INC for technical assistance. Please fill out and return the enclosed Product Registration/Warranty Card to PureFlow Technologies to register your warranty. 3

Section 1 Table of Contents TABLE OF CONTENTS Section 1....Table of Contents Section 2....Safety Guidelines Section 3...Parts List INSTALLATION PROCEDURES Section 4.. Raptor & Mounting Brackets Fuel Lines Section 5 A..Raptor to Filter Canister Section 5 B...High Flow Pickup Tube Section 5 C. Fuel Tank to Raptor Electrical Harness Section 6.......Electrical Harness Section 7..........Final Check List 4

Section 2 Safety Guidelines SAFETY GUIDELINES! NOTE: WARNING! WARNING IMPORTANT CAUTION: CAUTION: CAUTION: Proper location of the Raptor on the vehicle is essential. Consider hazards presented to the equipment by road debris and the elements. Please be sure to chock the vehicle s tires to prevent rolling. Disconnect the battery cables to both batteries before proceeding with the Raptor Fuel Pump installation. Use diesel fuel compatible thread sealer on all NPT tapered pipe thread fuel fitting connections! Vehicle frame rails should not be drilled into or welded upon. Wear safety glasses when operating power tools such as drills and grinders or when using a punch or chisel. Use common sense when routing fuel lines and electrical harnesses. Keep them away from hot exhaust components and/or moving parts. Properly secure lines to prevent chaffing. TYPICAL RAPTOR 150 INSTALLATION LAYOUT Figure 1 5

Section 3 Parts List Raptor RP-150 Parts List QTY DESCRIPTION IMAGE 1 INSTALLATION MANUAL 1 RAPTOR RP-150 FUEL PUMP 1 WIRING HARNESS 1 MOUNTING BRACKETS 1 SPACER BLOCK ( As needed to clear cables) MOUNTING FASTENERS (3) 3/8-16 X 4 ½ Lg. HHCS (3) 3/8 Flat Washer 1 Set (3) 3/8 Split Lock Washer (3) 3/8-18 Nuts (4) 5/16-18 X ¾ Lg. FH SHCS (4) 5/16 18 X 2 ¾ Lg. FH SHCS (If Spacer Block is used) 1 INLET FITTING -8JIC Male to ½ ORB 1 OUTLET FITTING -8 JIC Male to 3/8 NPT 1 FUEL LINE ½ 4-8 JIC SWIVEL TO ½ BARB 1 FUEL FITTING (For Filter Canister Inlet) 1 BUNDLE OF CABLE TIES 1 HIGH FLOW SUCTION TUBE 6

Section 4 Raptor Fuel Pump & Mounting Brackets Mounting the Bracket and Raptor 150 to the Truck s Frame NOTE: The Raptor 150 can be mounted on either the inside or the outside of the frame. Mounting inside the frame will give more protection from road debris. 4-1. Assemble the Raptor to the mounting bracket as shown (Fig. 2). Hold the assembly next to selected location on the frame to check for clearance. Adjust the Raptor up or down on the mounting bracket as necessary. To clear fuel lines or wiring on the frame, use the spacer block. 4-2. Loose assemble the mounting bracket, with Raptor attached, to the frame with the backing plate using 3/8 x 4 ½ bolts, lock washers, and nuts included in the kit.. After positioning the bracket, properly torque the fasteners. Figure 2 Typical Mounting Location of Raptor 150 Location may vary due to particular truck model and year. Figure 3 Step 4-3.. Install the 3/8 NPT x -8 flare fitting into the port marked OUT. Use diesel compatible thread sealer when installing this fitting. Properly torque the fitting. Step 4-4 Install the Boss o-ring X -8 SAE fuel fitting into the Raptor port marked IN. Verify the wire screen insert is in place before installing the fitting. Properly torque the fitting. 7

Section 5 Fuel Lines Section 5A: Connecting the Raptor 150 to the Filter Canister. 5A-1. Remove the Lift Pump and fuel supply line from the original factory fuel filter canister. Fuel Filter Canister Figure 4-A Figure 4-B 5A-2. Install the 2 hole mounting plate x -8 flare fitting with O-ring into the inlet port on the fuel filter canister with the original pump mounting screws. Properly torque the fitting. 5A-3 Measure and cut the length of fuel line required to connect the Raptor fuel Out fitting (Ref. Fig. 5) to the filter canister inlet port (Ref. Fig. 4-A & B). Connecting the Raptor 150 fuel outlet to the filter canister inlet. Fuel OUT The direction of the fuel lines reflect an outside the frame mounting location. The Raptor 150 can be mounted either inside or outside the frame. Figure 5 8

Section 5 Fuel Lines Connecting the Raptor 150 to the Filter Canister, cont d Lubricate the hose barb with oil. Push the fuel line completely onto the hose barb. Figure 6 Figure 7 5A-4. Install a -8 Swivel x 1/2" Push Lock fitting on each end of the new fuel line. 5A-5. Connect one end of the new line to the Raptor OUT port (Ref. Fig. 5). 5A-6. Carefully route the fuel line to the filter canister. Connect the -8 swivel to the In port fitting on the filter canister. (Ref. Figs. 4A & B). Properly torque the fitting. Section 5B: Installing the High Flow Pickup Tube The Raptor 150 includes a ½ suction tube to accommodate the high flows of this system. To install the ½ suction tube it is necessary to either drop the fuel tank or to lift the truck bed. VERY IMPORTANT: Before dropping the fuel tank or removing the truck bed, Careful consideration should be given when deciding the best location to install the High Flow pickup tube. Consider a location that will give the adequate clearance between the pickup tube fitting and the pickup bed. Also consider a location that will access fuel from the lowest point as well as closest to the rear of the fuel tank. Acceleration of the vehicle will cause the fuel to migrate toward the rear of the tank. NOTE: Should you choose to drop the fuel tank, remember to support the tank as it is when it is installed on the truck. If you let the tank rest flat on the floor, it will squash out and the pickup tube may be too short after the tank is re-installed in the truck to access fuel when the fuel level is low. The pickup tube, being cut too short may suck air when the fuel level drops below ¼ tank. NOTE: Should you choose to pull the pickup bed to access the tank. Disconnect the tail light wires, fuel tank filler tube, and any other accessories or components that may be secured to both the frame and bed. Caution: Properly support the truck bed to prevent serious injury or death! Figure 8 Figure 9 9

Section 5 Fuel Lines Installing the High Flow Pickup Tube 5B-1. After accessing the fuel tank, remove the collection basket. Figure 10 Figure 11 5B-2. Drill a 1-1/8 hole at the selected location in the fuel tank to install the pickup tube. Hold a container below the drill point to catch debris. Figure 12 Figure 13 5B-3. Assemble the pickup tube and -8 flare x 3/8 npt 90 0 fitting to the bulkhead fitting as shown in Figure 13. Use diesel compatible thread sealer when assembling the NPT fittings to the bulkhead fitting. 5B-4. Measure and cut the pickup tube to a length that will allow at least ¼ -5/16 clearance off the bottom of the tank.. It is advisable to put a 3/8 cross bore hole in the bottom of the pickup tube to prevent accidental blockage. 5B-5. Install the grommet into the pickup tube access hole. Lubricate the bulkhead fitting with motor oil and pressing firmly, insert the pickup tube assembly into the grommet. Be sure the bulkhead fitting has completely seated in the grommet. 5B-6. Reinstall the collection basket in the fuel tank. Figure 14 10

Section 5 Fuel Lines Section 5C: Connecting the Raptor 150 to the High Flow Pickup Tube. 5C-1. Measure and cut the length of fuel line required to connect the High Flow suction tube -8 outlet fitting to the Raptor fuel inlet port marked "In". Figure 15 5C-2. Install a -8 Swivel x 1/2" Push Lock fitting into each end of the fuel line. 5C-3. Connect one end of the fuel line just assembled to the High Flow suction tube -8 outlet fitting. Properly torque the fitting. 5C-4. Carefully route the fuel line from the High Flow suction tube and connect it to the Raptor port marked IN. Properly torque the fitting. 5C-5. Secure all fuel lines to prevent damage from abrasion. 5C-6. Re-install the truck bed. 11

Section 6 Electrical Harness The Raptor 150 Fuel Pump is equipped with a relay controlled wiring harness that is activated through the OE fuel pump connection! Figure 16 Securing the Relay and Fuse Holder to the Vehicle 6-1. Secure the relay and fuse holder to the vehicle on the firewall near the steering column or a more suitable location, if appropriate. Figure 17 Figure 18 Connecting to the ECM Lead 6-2. Disconnect the OE fuel pump lead from the ECM connection (Deutsch, two pin connector). Carefully route and connect the Raptor relay lead (Deutsch, two pin Connector) to the ECM pump lead. Figure 19 Figure 20 6-3. Route the wiring harness pump lead to the Raptor. Connect the Deutsch connector on the Raptor to the corresponding lead on the wiring harness. 12

Section 6 Electrical Harness Connecting the power supply leads to the alternator instead of the battery will create a corrosion free connection. Green (-) Red (+) Replace the Protective Cover Figure 21 Figure 22 6-2. Route the Red & Green power supply lead to the alternator Connect the Green (-) lead to the alternator Chassis Ground connection. Connect the Red (+) lead to the alternator Hot Lead battery connection. Connecting the power supply leads to the battery. 6-3 Connect the RED (+) lead to the POSITIVE (+) post of the driver's side battery. Connect the GREEN (-) lead to the NEGATIVE (-) post of the same battery. Green (-) Red (+) Figure 23 Connecting the Power Lead to the Raptor 6-4. Route the wiring harness to the Raptor. Connect the 2 pin Deutsch connector to the corresponding connector on the Raptor Figure 24 BE SURE TO PROPERLY ROUTE AND SECURE THE WIRING HARNESS TO THE VEHICLE. 13

Section 7 Final Check List INITIAL START PROCEDURE 7-1 Turn the starter key to the on/run position. Note: It may be necessary to momentarily engage the starter for the ECM to energize the Raptor Fuel Pump 7-2 While the Raptor Fuel Pump is on, bleed the fuel line to the filter canister by loosening the fuel line connection at the canister. As soon as the line is purged of air and fuel is observed, properly tighten the fuel fitting. NOTE: put a rag or shop towel over and around the fitting to prevent splatter. Catch all spilled fuel and dispose of properly. 7-3 Start engine! Adjusting the Pressure Regulator 7-4 To adjust the fuel pressure, if necessary, first loosen the lock nut on the regulator body adjustment screw. Using a flat blade screw driver, rotate the adjustment screw clock wise to increase pressure or counter clockwise to decrease pressure. Be careful not to loosen the regulator assembly base. When finished, properly torque the regulator adjustment screw! Properly tighten the adjustment lock nut when finished. Figure 25 RECHECK ALL FUEL FITTINGS FOR LEAKAGE AND PROPERLY TORQUE AS NECESSARY. BE SURE ALL FUEL LINES ARE PROPERLY ROUTED TO PROTECT FROM EXCESSIVE HEAT AND SECURED TO PROTECT FROM CHAFFING AND ABRASION. RECHECK ALL ELECTRICAL LINES, SECURE AS NECESSARY. NOTE: Should any installation problems arise, please call, toll free 1-877-463-4373, for assistance, Monday Friday, 8:00 am 5:00 pm CST. 14

NOTES 15